TM  5-6115-584-34 NAVFAC  P-8-622-34 TO-35C2-3-456-2 properly. The delivery valve holder must be assembled with a twelve point wrench, and retorqued to 0-80 ft-lbs. The cap nut must be retorqued to 55-60 ft-lbs. 7-19.  CYLINDER  BLOCK. a.  Clean  and  Inspect. (1)  Steam  clean  cylinder  block  to  remove  deposits of oil and dirt. Immerse block in solvent tank to clean out internal  passages. (2) Inspect top surface of cylinder block, the surface that mates with the cylinder head, for warping. Check both across cylinders and in line with cylinder. (3)   Use   magnetic   particle   method   to   check   the cylinder block for cracks. Replace block if cracked. (4)  Cylinder  walls  should  be  free  of  scratches,  pit- ting and scuffing. Check each cylinder with an inside reading micrometer  for  out-of  round  and  wear.  See  Table  1-2  for bore measurements. b.   Overhaul   and   Rebuild.   Always   de-glaze   cylinder walls. If necessary, hone or rebore the cylinder to fit the next available oversize piston. Pistons and rings are available in 0.005, 0.010, 0.020, 0.030 and 0.040 inch oversize. If cylin- ders  do  not  need  refinishing,  remove  any  existing  ridges from top of wall with a fine stone. c. Install. If the cylinder block requires replacement a new  set  of  injection  pump  shims  must  be  used  and  the injection  pump  must  be  re-timed.  The  shims  are  supplied with  the  replacement  cylinder  block.  Refer  to  paragraph 7-18 a. (3) for calculation of the shim thickness. 7-20.   FUEL   INJECTOR. All injector openings and injector nozzles must be capped when the injector is removed from the engine. a. Removal. (1)  Remove  fuel  lines  (3  and  7,  figure  7-1)  at  fuel injectors. (2) Remove screws (1, figure 7-45), washers (2) and retaining flanges (3). (3) Remove fuel injector (4), gasket (5), aapter (6), gasket (7), heat shield (8) and gasket (9). Separate injector from other components. Do not attempt to disassemble nozzles or adjust nozzle  pressure  without  the  proper  test  equip- ment. A nozzle pressure tester is essential to do Do not allow nozzle to spray against skin. Fuel under  nozzle  pressure  can  penetrate  flesh  and cause  a  serious  infection. b. Test. Install nozzle to be tested on a static fuel nozzle testing  fixture.  Increase  fuel  pressure  until  nozzle  opens. Opening pressure should be 1950  ± 25 psi for a new nozzle or 1750 ± 25 psi for a used nozzle (200 hours or more). If nozzle opening pressure is lower, adjust to 1950 psi for a new nozzle or 1750 psi for a used nozzle (see adjustment proce- dure). c.   Adjust. (1) Remove pipe plug (1, figure 7-46). (2) Loosen (do not remove) cover (2). (3)  Install  injector  nozzle  on  a  static  fuel  nozzle testing  fixture. (4) Insert a 5/32 inch hex socket key through hole in cover  (2). (5) Adjust opening pressure with hex key to correct pressure ( 1750 psi for a used injector, 1950 psi for a new injector). (6)  Tighten  cover  (2),  and  recheck  opening  pressure. d.    Disassemble. NOTE When  removing  and  disassembling  fuel  injec- tors,   separate   and   label   components   of   each injector.   Never   interchange   components   of injectors. Never clamp injector in a vise without soft jaws. (1) Secure injector in a holding fixture and remove nozzle cap nut (12, figure 7-46) and nozzle (9). NOTE Do  not  remove  nozzle  unless  replacement  is required. (2)  Install  nozzle  cap  nut  (12)  loosely  to  protect lapped  surfaces  of  injector  body. e.   Clean.   Clean   injectors   in   a   clean   room   on   a clean  work  bench.  Provide  a  van  of  clean  diesel  fuel  and this work. a   supply   of   lint-free   wiping   cloths.   Never   use   hard   or Change  7 7 - 4 1